Exhaust Fuel Addition Injector (For Dpf) Removal

Engine Hybrid System. Land Cruiser. Urj200, 202 Grj200 Vdj200
1Vd-Ftv Emission Control. Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

  4. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

  5. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

  6. REMOVE UPPER RADIATOR SUPPORT SEAL

  7. DRAIN ENGINE COOLANT

  8. REMOVE INTERCOOLER ASSEMBLY

  9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

  10. REMOVE NO. 1 AIR CLEANER HOSE

  11. REMOVE INTAKE AIR CONNECTOR

  12. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

  13. REMOVE AIR TUBE SUB-ASSEMBLY RH

  14. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH

  15. REMOVE AIR TUBE SUB-ASSEMBLY LH

  16. REMOVE NO. 1 GAS FILTER

  17. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET

  18. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH

  19. REMOVE NO. 1 AIR HOSE

  20. REMOVE NO. 3 AIR TUBE

  21. REMOVE NO. 2 AIR HOSE

  22. REMOVE NO. 4 AIR TUBE

  23. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

  24. DISCONNECT WATER HOSE SUB-ASSEMBLY

  25. REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)

  26. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

  27. DISCONNECT FUEL HOSE

  28. REMOVE NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)

  29. DISCONNECT ENGINE WIRE

  30. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

  31. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY

  32. REMOVE CYLINDER HEAD COVER SILENCER LH

  33. REMOVE NO. 2 FUEL INJECTOR PROTECTOR

  34. REMOVE CYLINDER HEAD COVER SILENCER RH

  35. REMOVE NO. 1 FUEL INJECTOR PROTECTOR

  36. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY

  37. DISCONNECT FUEL TUBE SUB-ASSEMBLY

  38. REMOVE FUEL INJECTOR SEAL

Exhaust Fuel Addition Injector (For Dpf) -- Removal


NOTICE:
When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.


1. PRECAUTION
NOTICE:
After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (Click here).


2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).


3. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 3 bolts and screw.

  1. Loosen the clip and remove the front fender splash shield LH.



4. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

  1. Remove the 3 bolts and 2 screws.

  1. Loosen the clip and remove the front fender splash shield RH.



5. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 10 bolts and No. 1 engine under cover.



6. REMOVE UPPER RADIATOR SUPPORT SEAL

  1. Remove the 7 clips and upper radiator support seal.



7. DRAIN ENGINE COOLANT
CAUTION:
Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
HINT:
Collect the coolant in a container and dispose of it according to the regulations in your area.

  1. Loosen the radiator drain cock plug.

  1. Remove the radiator reservoir cap to drain the coolant in the radiator.



  1. Loosen the oil filter bracket drain cock plug to drain the coolant in the engine.


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal

  1. Tighten the radiator drain cock plug by hand.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Tighten the oil filter bracket drain cock plug.

    Torque:
    13 N*m{133 kgf*cm, 10 ft.*lbf}


8. REMOVE INTERCOOLER ASSEMBLY
(Click here)


9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp.

  1. Disconnect the mass air flow meter connector and using a clip remover, detach the wire harness clamp from the air cleaner cap.

  1. Detach the 4 clamps and remove the air cleaner cap.



10. REMOVE NO. 1 AIR CLEANER HOSE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp and remove the No. 1 air cleaner hose.



11. REMOVE INTAKE AIR CONNECTOR


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal

  1. w/ Viscous Heater:
    Disconnect the 2 connectors from the viscous with magnet clutch heater and water temperature sensor.

    Text in Illustration
    *A
    		w/ Viscous Heater

  1. w/o Viscous Heater:
    Disconnect the connector from the water temperature sensor.

  1. Using a clip remover, detach the 3 wire harness clamps.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the 2 hose clamps and remove the 2 bolts and intake air connector.



12. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the wire harness clamp from the No. 2 engine oil level dipstick guide.



    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal

  1. Disconnect the ventilation hose from the cylinder head cover RH.

    Text in Illustration
    *A
    		w/ DPF
    *B
    		w/o DPF

  1. Remove the 2 bolts and No. 2 engine oil level dipstick guide.

  1. Remove the O-ring from the No. 2 engine oil level dipstick guide.



13. REMOVE AIR TUBE SUB-ASSEMBLY RH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp.

  1. Remove the air tube from the throttle body.



14. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the throttle position sensor connector.

  1. Disconnect the throttle motor connector.

  1. Remove the 2 bolts, 2 nuts and throttle body.

  1. Remove the gasket from the intake pipe.



15. REMOVE AIR TUBE SUB-ASSEMBLY LH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp.

  1. Remove the air tube from the throttle body.



16. REMOVE NO. 1 GAS FILTER


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the hose from the intake pipe.

  1. Remove the No. 1 gas filter.



17. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. for Manual Transmission:

    1. Remove the bolt and disconnect the clutch tube to release cylinder 2 way from the No. 3 intercooler support bracket.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and No. 3 intercooler support bracket.



18. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the throttle position sensor connector.

  1. Disconnect the throttle motor connector.

  1. Remove the 2 bolts, 2 nuts and throttle body.

  1. Remove the gasket from the intake pipe.



19. REMOVE NO. 1 AIR HOSE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp and remove the No. 1 air hose.



20. REMOVE NO. 3 AIR TUBE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the wire harness from the clamp.

  1. Remove the nut and ground wire.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the bolt and disconnect the wire harness bracket.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp and remove the bolt and No. 3 air tube.



21. REMOVE NO. 2 AIR HOSE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp and remove the No. 2 air hose.



22. REMOVE NO. 4 AIR TUBE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the bolt and disconnect the suction hose.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp and remove the bolt and No. 4 air tube.



23. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the ventilation hose from the oil separator.

  1. Loosen the hose clamp.

  1. Remove the bolt and No. 2 air cleaner pipe.



24. DISCONNECT WATER HOSE SUB-ASSEMBLY


Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal
Text in Illustration
*A
w/ Rear Heater
*B
w/o Rear Heater


25. REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts and disconnect the 4 water hose ends, and then remove the heater water pipe.



26. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp.

  1. Remove the bolt and No. 1 air cleaner pipe.



27. DISCONNECT FUEL HOSE


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal

  1. w/ DPF:

    Text in Illustration
    *a
    		for Fuel Filter with Heater
    *b
    		for Fuel Filter without Heater


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal

  1. w/o DPF:

    Text in Illustration
    *a
    		for Fuel Filter with Heater
    *b
    		for Fuel Filter without Heater


28. REMOVE NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and disconnect the 2 water hose ends, and then remove the No. 3 water by-pass pipe.



29. DISCONNECT ENGINE WIRE


  1. LH Side:



      Land Cruiser. Urj200, 202 Grj200 Vdj200

    1. Disconnect the 4 connectors.

    2. Using a clip remover, detach the 3 wire harness clamps.



      3. Land Cruiser. Urj200, 202 Grj200 Vdj200

    3. Disconnect the 2 connectors.

    4. Using a clip remover, detach the 3 wire harness clamps.



    5. Disconnect the 8 connectors.


      Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal


      Text in Illustration
      *A
      		w/ DPF
      		*B
      		w/o DPF

    6. Remove the bolt and engine wire harness bracket labeled B.

    7. Using a clip remover, detach the wire harness clamp labeled D.

    8. Remove the 2 bolts and disconnect the engine wire protector labeled A.

    9. for RHD:
      Disconnect the wire harness from the wire harness clamp holder labeled C.



  1. RH Side:



    1. Disconnect the 7 connectors.


      Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal


      Text in Illustration
      *A
      		w/ DPF
      		*B
      		w/o DPF

    2. Using a clip remover, detach the wire harness clamp.

    3. Remove the 3 bolts and disconnect the wire harness protector labeled A.

    4. Remove the bolt and wire harness bracket labeled B.

    5. Remove the screw grommet, nut and glow plug wire harness labeled C.



      6. Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal

    6. for RHD:
      Disconnect the wire harness from the wire harness clamp holder.

      Text in Illustration
      *A
      		w/ DPF
      *B
      		w/o DPF

    7. for RHD:
      Remove the bolt and wire harness clamp holder.



  1. Rear Side:



      Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal

    1. Using a clip remover, detach the wire harness clamp.

      Text in Illustration
      *A
      		w/ DPF
      *B
      		w/o DPF

    2. Remove the 2 bolts and 2 ground wires labeled C.

    3. Remove the 2 bolts and disconnect the engine wire harness protector labeled B.

    4. w/ DPF:
      Disconnect the 3 connectors.

    5. w/o DPF:
      Disconnect the connector.

    6. Remove the screw grommet, nut and disconnect the glow plug wire harness labeled A.



30. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the 2 vacuum hoses.

  1. Remove the bolt and vacuum switching valve.



31. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the 2 vacuum hoses.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 3 bolts and vacuum transmitting pipe.



32. REMOVE CYLINDER HEAD COVER SILENCER LH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts and cylinder head cover silencer.



33. REMOVE NO. 2 FUEL INJECTOR PROTECTOR


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Detach the hose clamp.

  1. Remove the bolt and No. 2 fuel injector protector.



34. REMOVE CYLINDER HEAD COVER SILENCER RH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts and cylinder head cover silencer.



35. REMOVE NO. 1 FUEL INJECTOR PROTECTOR


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the bolt and No. 1 fuel injector protector.



36. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal

  1. Disconnect the 2 exhaust fuel addition injector connectors.

    Text in Illustration
    *A
    		for Bank 1
    *B
    		for Bank 2


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal

  1. Remove the 2 bolts, 2 washers and 2 nozzle holder clamps.

    Text in Illustration
    *A
    		for Bank 1
    *B
    		for Bank 2
    *1
    		Washer
    *2
    		Nozzle Holder Clamp

  1. Remove the 2 exhaust fuel addition injectors and 2 gaskets.



37. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal

  1. Turn the 2 retainers shown in the illustration.

    Text in Illustration
    *A
    		for Bank 1
    *B
    		for Bank 2
    NOTICE:
    1. Check for foreign matter on the fuel tube around the fuel tube connector. Clean it if necessary. Foreign matter can affect the ability of the O-ring to seal the fuel tube connector and fuel pipe.
    2. Do not use any tools to separate the fuel tube connector and fuel pipe.
    3. Do not forcefully bend, kink or twist the nylon tube.
    4. Keep the fuel tube connector and fuel pipe free from foreign matter.
    5. Put the fuel tube connector and fuel pipe in plastic bags to prevent damage and contamination.


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal

  1. Disconnect the 2 fuel tube connectors from the exhaust fuel addition injector.

    Text in Illustration
    *1
    		Fuel Tube Connector
    *2
    		Exhaust Fuel Addition Injector
    *3
    		Retainer
    *4
    		O-Ring


38. REMOVE FUEL INJECTOR SEAL


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Exhaust Fuel Addition Injector (For Dpf) Removal

  1. Remove the 2 fuel injector seals.

    Text in Illustration
    *1
    		Fuel Injector Seal